Washing machine shipping system and method

ABSTRACT

Washing machine shipping systems that inhibit movement of one or more moveable component with respect to one or more stationary component of a washing machine during shipping and handling of the washing machine. The shipping systems engage a moveable component, such as a motor or a basket, to substantially prevent side-to-side and/or vertical movement of the moveable component with respect to a stationary component, such as a cabinet or frame, during shipment. In an exemplary embodiment, the shipping system is removed from the washing machine for installation of the washing machine at the consumer&#39;s residence. In some exemplary embodiments, the washing machine system engages an outer surface of an external rotor of a motor to substantially prevent side-to-side and/or vertical movement of the motor with respect to the washing machine cabinet.

RELATED APPLICATIONS

The present application claims the benefit of U.S. provisionalapplication Ser. No. 61/318,072, filed on Mar. 26, 2010 which isincorporated herein by reference in its entirety.

BACKGROUND

Washing machines are commonly manufactured by production facilities andtransported to retail outlets via trucks or by rail. Subsequent to asale to a consumer, a washing machine is transported from the retailoutlet to the consumer's residence, often by a truck. Washing machinescan include moveable components such as tubs, baskets, and motors thatmove with respect to stationary components, such as cabinets and supportframes during operation of the washing machine.

SUMMARY

The present application discloses exemplary embodiments of washingmachine shipping systems that inhibit movement of one or more moveablecomponent with respect to one or more stationary component of a washingmachine during shipping and handling of the washing machine. Theshipping systems engage a moveable component, such as a motor or abasket, to substantially prevent side-to-side and/or vertical movementof the moveable component with respect to a stationary component such asa cabinet or frame. In an exemplary embodiment, the shipping system isremoved from the washing machine for installation of the washing machineat the consumer's residence. In some exemplary embodiments, the washingmachine system engages an outer surface of an external rotor of a motorto substantially prevent side-to-side and/or vertical movement of themotor with respect to the washing machine cabinet.

Multiple exemplary embodiments of shipping systems are disclosed by thepresent application. Shipping systems in accordance with the presentinvention may include any combination or subcombination of the featuresor concepts disclosed by the present application.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which are incorporated in and constitute apart of the specification, embodiments of the invention are illustrated,which, together with a general description of the invention given above,and the detailed description given below, serve to example theprinciples of this invention.

FIG. 1 is an exploded side view, in cross-section, of a washing machineand a shipping system including an optional engagement device and aninterface.

FIG. 2 is a side view, in cross-section, of the washing machine andshipping system of FIG. 1 illustrated in an assembled state;

FIG. 3 is a perspective view of a rotor of the washing machine shown inFIG. 1 illustrating rotor fins.

FIG. 4 is a perspective view of the engagement device that is includedin the shipping system shown in FIG. 1;

FIG. 5 is a perspective view of the engagement device that is includedin the shipping system shown in FIG. 4 illustrated in an engagedposition with the rotor of FIG. 3;

FIG. 6 is a perspective view of the interface that is included in theshipping system shown in FIG. 1;

FIG. 7 is a side view, in cross-section, of a second embodiment of awashing machine and a shipping system;

FIG. 8 is a side view, in cross-section, of a third embodiment of awashing machine and a shipping system;

FIG. 9 is a side view, partially in cross-section, of a secondembodiment of an interface illustrating a leveling foot boot;

FIG. 10 is a top plan view of another embodiment of an interfaceillustrating intersecting cross members;

FIG. 11 is a side elevational view of the interface of FIG. 10;

FIG. 12 is a top plan view of another embodiment of an interfaceillustrating diagonal frame members;

FIG. 13 is a side elevational view of the interface of FIG. 12;

FIG. 14 is a top plan view of another embodiment of an interfaceillustrating cross members forming a support frame;

FIG. 15 is a side elevational view of the interface of FIG. 14;

FIG. 16 is a top plan view of another embodiment of an interfaceillustrating a cross member supporting a support frame;

FIG. 17 is a side elevational view of the interface of FIG. 16.

FIG. 18 is a top plan view of another embodiment of an interfaceillustrating intersecting support members and a resilient member;

FIG. 19 is a side elevational view of an interface of FIG. 18; and

FIG. 20 is a top plan view of the interface of FIG. 18 shown in aninstalled position within a washing machine.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with occasional reference tothe specific embodiments of the invention. This invention may, however,be embodied in different forms and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments are providedso that this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The terminology used in thedescription of the invention herein is for describing particularembodiments only and is not intended to be limiting of the invention. Asused in the description of the invention and the appended claims, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities ofdimensions such as length, width, height, and so forth as used in thespecification and claims are to be understood as being modified in allinstances by the term “about.” Accordingly, unless otherwise indicated,the numerical properties set forth in the specification and claims areapproximations that may vary depending on the desired properties soughtto be obtained in embodiments of the present invention. Notwithstandingthat the numerical ranges and parameters setting forth the broad scopeof the invention are approximations, the numerical values set forth inthe specific examples are reported as precisely as possible. Anynumerical values, however, inherently contain certain errors necessarilyresulting from error found in their respective measurements.

The description and figures disclose shipping systems and methods forwashing machines. Generally, the shipping system is configured torestrain movable internal components of the washing machine and inhibitmovement of the movable internal components during shipping and handlingof the washing machine. In one exemplary embodiment, the moveableinternal components may be restrained such that some movement of theinternal components relative to a cabinet of the washing machine isallowed during shipping and handling. However, the restraint limitsmovement of the internal components with respect to the cabinet toprevent damage to the internal components. In another exemplaryembodiment, the moveable internal components are secured to prevent themoveable internal components from moving with respect to the cabinetduring shipping. Once the washing machine arrives at a finaldestination, the shipping system is removed from the washing machine.Some portions of the shipping system may be recycled and other portionsof the shipping system may be retained for use in subsequent maintenanceand repair efforts.

The term “washing machine” as used herein, is defined to mean a machinedesigned to wash laundry items, such as clothing, towels and sheets,that uses water as the primary cleaning solution.

Referring now to FIG. 1, a washing machine shipping system, illustratedgenerally at 10, is shown with an associated washing machine 12. Thewashing machine shipping system 10 includes an engagement device 14 andan interface 16. In the FIG. 1 example, the engagement device 14 and theinterface 16 are illustrated as separate components. However, theengagement device 14 may be incorporated into the interface 16. Thewashing machine shipping system 10 will be discussed in more detailbelow.

Referring again to FIG. 1, the illustrated washing machine 12 is a “toploading” machine. The term “top loading”, as used herein, is defined tomean that an internal basket configured to retain laundry items duringthe washing cycle is oriented in an upright position and that thelaundry items enter the basket from a top opening in the washing machine10. However, the concepts of the washing machine shipping system can beapplied to any type of washing machine. The illustrated washing machine12 includes a cabinet 20, a tub 22, a motor assembly 24 and a basket 26.

As shown in FIG. 1, the cabinet 20 is configured to provide an enclosurefor the internal components of the washing machine 12. The illustratedcabinet 20 includes a top surface 30, side surfaces 32 and bottom frameassemblies 34. However, the cabinet 20 can take a variety of differentforms. The cabinet 20 can be made from sheet metal and covered with afinish such as an enamel based finish. The cabinet can be made from awide variety of different materials and/or combinations of materials.Examples of suitable materials for the cabinet include, but are notlimited to plastic, fiberglass reinforced plastic, any type of sheetmetal, etc. The cabinet 20 may have any finish. The cabinet 20 can bemade from stainless steel sheet metal, and can have other desiredfinishes, such as for example a clear lacquer finish. The top surface 30of the cabinet includes an opening 36. The opening will be discussed inmore detail below. While the illustrated embodiment shows the cabinet ashaving a generally rectangular cross-sectional shape, it should beappreciated that the cabinet can have other cross-sectional shapes.

Referring again to the example of FIG. 1, the illustrated tub 22 issuspended within the cabinet 20 and is configured to retain water usedfor washing the laundry items. The tub 22 can take a wide variety ofdifferent forms and can be made from a wide variety of differentmaterials. The tub 22 may be generally cylindrical with an open top 40as shown, but may take a variety of different shapes. The tub may bemade from plastic/polymeric materials, or metals, such as steelstainless steel, and aluminum. Preferably, the tub is made from amaterial that is resistant to corrosion when exposed to water or atleast the inside surface of the tub is coated with a material that isresistant to corrosion when exposed to water.

As shown in the example of FIG. 1, the tub 22 is connected to ends of aplurality of suspension devices 38. The other ends of the suspensiondevices 38 being coupled to the cabinet 20. In the illustratedembodiment, the suspension devices 38 are coupled to the top surface 30of the cabinet 20. The suspension devices 38 are configured to allowsome vertical movement of the tub 22 with respect to the cabinet 20while limiting rotational movement of the tub 22 with respect to thecabinet 20. However, the tub 22 may be coupled to the cabinet 20 in awide variety of different ways. In the illustrated embodiment, thesuspension devices 38 are a combination of rods, springs and attachmentmechanisms. In other embodiments, the suspension devices 38 can be anydesired structure, mechanism or device sufficient to suspend the tub 22within the cabinet 20. The suspension devices 38 may allow verticalmovement of the tub 22 with respect to the cabinet 20 or otherwisecouple the tub 22 to the cabinet 20. The tub 22 has a top opening 40.

Referring again to the example illustrated by FIG. 1, the motor assembly24 is positioned below the tub 22. The illustrated motor assembly 24 isconfigured to rotate the basket 26 via shaft 42. However, the motorassembly 24 may take a wide variety of different forms and may becoupled to the basket 26 in many different ways. The illustrated motorassembly 24 includes an external rotor 44 connected to the shaft 42 witha stator of the motor being secured to the tub 22 by a connection 45.Alternatively, the motor assembly 24 may include an external stator thatis secured to the tub 22 with the internal rotor connected to shaft 42.Any rotor/stator configuration and coupling to the basket 26 may beemployed. The illustrated rotor 44 is configured to enclose the motorassembly 24 and includes a hub 46 and a plurality of optional spacedapart fins 48 radiating from the hub 46, as shown in FIG. 3. In theillustrated embodiment, the hub 46 has a circular cross-sectional shape.Alternatively, the hub 46 can have other cross-sectional shapes,including the non-limiting example of a square cross-sectional shape.The hub 46 has a hub diameter HD. In the illustrated embodiment, the hubdiameter HD is approximately 1.25 inches. In other embodiments, the hubdiameter HD can be more than or less than approximately 1.25 inches.

Referring again to FIG. 3, the illustrated hub 46 includes optional gaps50 between the spaced apart fins 48. The gaps 50 will be discussed inmore detail below. While the embodiment illustrated in FIG. 3 shows aquantity of ten spaced apart fins 48, it should be appreciated thatother embodiments of the rotor 44 can include more or less than tenspaced apart fins 48.

Referring again to the example illustrated by FIG. 1, the basket 26 ispositioned within the tub 22 and configured to retain the laundry itemsduring the washing cycle. The basket 26 can take a wide variety ofdifferent foams and can be made from a wide variety of differentmaterials. The basket 26 may be generally cylindrical with an open topas shown, but may take a variety of different shapes. The tub may bemade from plastic/polymeric materials, or metals, such as steel,stainless steel, and aluminum. Preferably, the tub is made from amaterial that is resistant to corrosion when exposed to water or the tubis coated with a material that is resistant to corrosion when exposed towater.

As shown in the example illustrated by FIG. 1 and discussed above, theillustrated washing machine shipping system 10 includes the engagementdevice 14 and the interface 16. In this embodiment, the engagementdevice 14 is configured to engage the rotor 44 (or other moveablecomponent) and the interface. For example, the engagement device may beconfigured to mate with an external surface of the rotor 44 and beconfigured to mate with a portion of the interface 16. The interface 16couples the engagement device 14 and the rotor 44 to another componentof the washing machine 12, such as the cabinet 20 and/or the bottomframe assembly 34. In some exemplary embodiments, the interface is atleast partially retained within the cabinet of the washing machine forthis coupling. The coupling of the rotor 44 (or other moveablecomponent) to the cabinet 20, bottom frame assembly 34 or other fixedcomponent of the washing machine 12 prevents or substantially reducesside-to-side movement and/or vertical movement of the suspended tub 22and motor assembly 24 during shipping and handling of the washingmachine 12. The interface and/or the engagement device are removablefrom the cabinet 20 after the shipping and handling for installation ofthe washing machine at the consumer's residence.

FIG. 4 illustrates an exemplary embodiment of an engagement device 14.In the illustrated embodiment, the engagement device 14 is configured toengage the tub 46 and fins 48 of the rotor 44. However, the engagementdevice 14 can be configured to engage the rotor 44 (or other moveablecomponent of the washing machine 12) in a wide variety of differentways. In an exemplary embodiment, the engagement device 14 is configuredto engage the outer surface of the rotor 44 by pushing the engagementdevice linearly onto the rotor in the vertical direction and todisengage the outer surface of the rotor 44 by pulling the engagementdevice linearly downward away from the rotor 44.

The illustrated engagement device 14 includes an opening 52 or recesshaving a generally circular cross-sectional shape. The cross-sectionalshape of the opening 52 may correspond to the cross-sectional shape ofthe hub 46 of the rotor 44. In other embodiments, the cross-sectionalshape of the opening can be other desired shapes sufficient to fit withthe cross-sectional shape of the hub 46 of the rotor 44. The opening 52has an opening diameter ID. The opening diameter ID is configured togenerally correspond to the hub diameter HD of the hub 46 such that a“close fit” is achieved. The term “close fit”, as used herein, isdefined to mean that the difference between the hub diameter HD and theopening diameter ID is within a range of from about 0.001 inches toabout 0.025 inches.

Referring again to FIG. 4, the illustrated engagement device 14 has alength LED. In the illustrated embodiment, the length LED of theengagement device 14 is in a range of from about 1.50 inches to about3.0 inches. In other embodiments, the length LED of the engagementdevice 14 can be less than about 1.5 inches or more than about 3.0inches.

As shown in FIG. 4, the illustrated engagement device 14 has an upperend 54 and a lower end 56. A plurality of slots 56 extend from the upperend 54 toward the lower end 56 in a direction generally parallel to thelength LED of the engagement device 14. The plurality of slots 56defines a plurality of teeth 58. The plurality of slots 56 and theplurality of teeth 58 are configured to engage the rotor 44 such thatthe spaced apart fins 48 fit within the slots 56 and the teeth 58 fit inthe gaps 50 between the spaced apart fins 48. In the illustratedembodiment, the engagement device 14 has the same quantity of slots 56as the quantity of spaced apart fins 48 of the rotor 44. However, inother embodiments, the engagement device 14 can have a quantity of slots56 that is more or less than the quantity of spaced apart fins 48.

FIG. 5, illustrates the exemplary engagement device 14 is shown in anengaged position with the rotor 44. As discussed above, in this positionthe spaced apart fins 48 fit within the slots 56 and the teeth 58 fit inthe gaps 50 between the spaced apart fins 48. While the embodiment shownin FIG. 5 illustrates the upper end 54 of the engagement device 14seating against a lower surface 60 of the rotor 44, it should beappreciated that in other embodiments, the engagement device 14 can beconfigured to prevent or substantially reduce side-to-side movementand/or vertical movement of the suspended tub 22 and motor assembly 24without the upper end 54 of the engagement device 14 seating against alower surface 60 of the rotor 44.

Referring to the example illustrated by FIG. 4, the illustratedengagement device 14 includes optional opposing apertures 57. Theopposing apertures 57 are configured for insertion of a tool, such asthe non-limiting example of a screwdriver, for use in preventingrotation of the engagement device 14. In this manner, the engagementdevice 14 can engage the rotor 44 and prevent rotation of the rotor 44during servicing of the washing machine after the shipping and handlingof the washing machine and removal of the interface. Accordingly, theengagement device 14 can function as a maintenance and service tool forthe washing machine 12.

Referring again to the example illustrated by FIG. 1, the washingmachine shipping system 10 includes the interface 16. The interface 16can take a wide variety of different forms. The interface 16 can be anystructure configured to couple a moveable component, such as the motorassembly 24, the tub 22, or basket to a stationary component such as thecabinet 20 and the bottom frame assembly 34, either directly or throughthe engagement device 14. The interface 16 may be a framework formedfrom frame members, such as wooden frame members and/or may comprise oneor more members that are molded or otherwise formed to match theshape(s) of one or more components of the washing machine. The interface16 can be made from a wide variety of different materials orcombinations of materials. In the illustrated exemplary embodiment, theinterface 16 is configured to be attached to a component of the washingmachine 12 and to support the engagement device 14 during shipping andhandling of the washing machine 12.

In the example illustrated by FIG. 6, the interface 16 is a frameworkthat includes a cross member 70 attached to opposing support members 72.The cross member 70 includes a recess 74. The recess 74 is configured tocontain the engagement device 14. In the illustrated embodiment, therecess 74 has a circular cross-sectional shape generally correspondingto the circular cross-sectional shape of the engagement device 14. Itshould be appreciated that in other embodiments, the recess 74 can haveother cross-sectional shapes corresponding to the cross-sectional shapeof the engagement device 14. Referring to FIGS. 1 and 6, the recess 74is positioned on the cross-member such that the engagement device 14engages the rotor 44, as described above, when the engagement device 14is contained in the recess 74.

In the illustrated embodiment, the cross member 70 and the supportmembers 72 are made of wood. Manufacturing the cross member 70 and thesupport members 72 from wood advantageously adds to the recyclability ofthe shipping system 10. However, in other embodiments, the cross member70 and the support members 72 can be made from other desired materials.

Referring again to FIG. 6, the illustrated support members 72 includecutouts 76. The cutouts 76 are configured as a clearance space forleveling legs 78 positioned on the bottom frame 34 of the cabinet 20, asshown in FIG. 1. The positions of the leveling legs 78 in the cutouts 76couples or sets the relative position of the interface 16 with respectto the cabinet 20 and bottom frame 34. The cutouts 76 can have anydesired cross-sectional shape.

As shown in FIG. 6, the framework 16 can include optional pads 80attached to the ends of the support members 72. The optional pads 80 areconfigured to cushion the washing machine 12 against impact duringshipping and handling. In the illustrated embodiment, the optional pads80 are made from layered cardboard. In other embodiments, the optionalpads 80 can be made from other materials, such as the non-limitingexample of rubber or foam. The optional pads 80 can be attached to thesupport members in any desired manner.

Referring again to FIG. 1, washing machine 12 may be prepared forshipping by the following process. First, the engagement member 14 ispositioned to engage the fins of the rotor 44 as discussed above. Next,the interface 16 is positioned such that the engagement member 14 iscontained within the recess 74 of the interface 16. The interface 16 israised into the cabinet 20 such that the cross-member 70 of theinterface 16 is positioned between the bottom frames 34 of the cabinet.In the illustrated embodiment, the cross-member 70 of the interface 16is retained within the cabinet as a result of a friction fit with thebottom frame 34 of the cabinet 20. In other embodiments, the interface16 can be retained within the cabinet 20 by other desired structures ormechanisms, such as for example, clips or clamps. The shipping system10, assembled to the washing machine 12 is illustrated in FIG. 2. Inthis position, the shipping system 10 is configured to prevent orsubstantially reduce side-to-side movement and/or vertical movement ofthe suspended tub 22 and motor assembly 24 during shipping and handlingof the washing machine 12.

Referring now to FIG. 7, another embodiment of a washing machineshipping system is illustrated. In this embodiment, a washing machineshipping system 110 includes a damping element 182. As will be describedin more detail below, the shipping system 110 and the damping element182 function together to secure a tub 122 and a motor assembly 124 inplace within a cabinet 120 of a washer 112 during shipping and handling.In the illustrated embodiment, the shipping system 110, cabinet 120, tub122 and motor assembly 124 are the same as, or similar to, the shippingsystem 10, cabinet 20, tub 22 and motor assembly 24 discussed above andillustrated in FIG. 1. However, in other embodiments, the shippingsystem 110, cabinet 120, tub 122 and motor assembly 124 can be differentfrom the shipping system 10, cabinet 20, tub 22 and motor assembly 24.

Referring again to FIG. 7, the damping element 182 is formed of a sleeve184 of resilient material that is stretched over and attached to the tub122. The sleeve 184 may be attached to the tub 122 in any desiredmanner, including the non-limiting examples of using mechanicalfasteners and/or adhesives or by a friction fit. While the embodimentillustrated in FIG. 7 shows the damping element 182 as having alatticework pattern, it should be appreciated that the damping element182 can have other desired patterns or a solid sheet with no pattern.

In the illustrated embodiment, the damping element 182 is made from afibrous polymeric material, such as for example polyester. In otherembodiments, the damping element 182 can be made from other desiredmaterials, including the non-limiting examples of a polyester olefinblend, polyethylene terephthalate, polybutylene terephthalate, apolyethylene terephthalate and polypropylene blend, a polybutyleneterephthalate and polypropylene blend and combinations thereof. In stillother embodiments, the damping element 182 can be made from laminatedmaterials including a core layer of fiberglass reinforced polymermaterial sandwiched between layers of polyester material.

The use of polymeric materials provides the damping element 182 withexcellent resiliency and wear resistance to provide a long service life.At the same time, the acoustic properties of the fibrous polymericmaterial may be tuned to better control noise and vibration. This may bedone by adjusting the density as well as the diameter and length of thefibers utilized in the damping element 182. It should also beappreciated that the damping element 182 can be further tuned to providea desired spring rate for maximizing the damping of the horizontalenergy or motion of the tub 122 within the cabinet 120.

Referring again to FIG. 7, a gap 186 is formed between the dampingelement 184 and the cabinet 120. The gap 186 is configured so as to notimpair the rotational torque movement of the tub 122 during start andstop movements of the washing machine 112.

As noted above, the shipping system 110 and damping element 182 arepositioned as illustrated in FIG. 7 to prevent or inhibit horizontalshifting and/or vertical movement of the tub 122 in the cabinet 120during shipping. Once the washer 112 is permanently positioned, theshipping system 110 is removed while the damping element 182 remainspositioned around the tub 122 for the life of the washer 112.

Referring now to FIG. 8, another embodiment of a washing machineshipping system is illustrated. In this embodiment, a washing machineshipping system 210 includes a damping element 282 and a removable plug288. As will be described in more detail below, the shipping system 210,damping element 282 and plug 288 function together to secure a tub 222and a motor assembly 224 in place within a cabinet 220 of a washer 212during shipping and handling. In the illustrated embodiment, theshipping system 210, cabinet 220, tub 222, motor assembly 224 anddamping element 282 are the same as, or similar to, the shipping system110, cabinet 120, tub 122, motor assembly 124 and damping element 182discussed above and illustrated in FIG. 7. However, in otherembodiments, the shipping system 210, cabinet 220, tub 222, motorassembly 224 and damping element 282 can be different from the shippingsystem 110, cabinet 120, tub 122, motor assembly 124 and damping element182.

Referring again to FIG. 8, the removable plug 288 includes a lowerportion 290 that is sized, shaped and contoured to fit snugly in a topopening 240 of the tub 222. The removable plug 288 also includes anupper portion 292 that is sized, shaped and contoured to fit snugly inan opening 236 in the top surface 230 of the cabinet 220. Optionally,the upper portion 292 can include a flat sidewall segment (not shown)matching the shape of the opening 236. The flat sidewall segmentfunctions to lock the removable plug 288 in position.

Since the plug 288 fits snugly in both the opening 236 of the cabinet220 and the tub 222 of the washing machine 212, it should be appreciatedthat the plug 288 may function to substantially prevent horizontalmovement and/or vertical movement of the tub 222 relative to the cabinet212 during shipping and handling of the washing machine 212. The plug288 can be made from any desired material including, but not limited to,expanded polystyrene, molded plastic, cardboard, and mixtures thereof.

As noted above, the shipping system 210, damping element 282 and plug288 are positioned as illustrated in FIG. 8 to prevent or inhibithorizontal shifting and/or vertical movement of the tub 222 in thecabinet 220 during shipping and handling. Once the washer 212 ispermanently positioned, the shipping system 210 and the plug 288 areremoved while the damping element 282 remains positioned around the tub222 for the life of the washer 212.

Another exemplary embodiment is illustrated in FIG. 9. In thisembodiment, the interface 316 comprises a framework that is attached toa bottom frame 334 of the cabinet 320 using a boot 394. As shown in FIG.9, a leveling leg 378 is attached to the bottom frame 334 of the cabinet320. In the illustrated embodiment, the framework 316, cabinet 320,bottom frame 334 and leveling leg 378 are the same as, or similar to,the interface 16, cabinet 20, bottom frame 34 and leveling leg 78discussed above and illustrated in FIG. 9. Alternatively, the interface316, cabinet 320, bottom frame 334 and leveling leg 378 can be differentfrom the interface 16, cabinet 20, bottom frame 34 and leveling leg 78.

Referring again to FIG. 9, the boot 394 includes an upper portion 395and a lower portion 396. The upper portion 395 has a circularcross-sectional shape generally corresponding to the shape of theleveling leg 378. The upper portion 395 of the boot 394 is configuredfor positioning over the leveling leg 378 such that a friction fitresults between the upper portion 395 and the leveling leg 378. Thelower portion 396 is attached to the upper portion 395 and has a conicalshape. The combination of the friction fit of the upper portion 395 tothe leveling leg and the conical shape of the lower portion 396 providesfor retention of a support member 372 to the bottom frame 334 of thecabinet 320. The boot 394 and the interface 316 are removed after thewashing machine is permanently positioned. The boot 394 can be made fromany desired material, including the non-limiting examples of rubber orpolymeric materials.

Referring now to FIGS. 10 and 11, another embodiment of a framework thatmay be used as the interface is illustrated generally at 416. In thisembodiment, the engagement device 14 may be omitted. In this embodiment,opposing support members 472 are connected to intersecting diagonalcross members 470. The diagonal cross members 470 include cutouts 471.The cutouts 471 are sized to correspond with the outer diameter of arotor 444 of the motor assembly (not shown). As shown in FIG. 11, therotor 444 seats within the cutouts 471. In this position, the cutouts471 and the diagonal cross members 470 support the rotor 444, therebypreventing or substantially reducing side-to-side movement and/orvertical movement of a suspended tub and motor assembly during shippingand handling of the washing machine.

Referring now to FIGS. 12 and 13, another embodiment of a framework thatmay be used as the interface is illustrated generally at 516. In thisembodiment, the engagement device 14 may be omitted. In this embodiment,cross member 570 spans and connects opposing support members 572. Thecross member 570 supports diagonal frame members 573. The diagonal framemembers 573 are positioned to correspond with the outer diameter of arotor 544 of the motor assembly (not shown). As shown in FIG. 13, therotor 544 seats on the cross member 570 and within the diagonal framemembers 573. In this position, the diagonal frame members 573 supportthe rotor 544, thereby preventing and/or substantially reducingside-to-side movement and vertical movement of a suspended tub (notshown) and motor assembly during shipping and handling of the washingmachine.

Referring now to FIGS. 14 and 15, another embodiment of a framework thatmay be used as the interface is illustrated generally at 616. In thisembodiment, the engagement device 14 may be omitted. In this embodiment,cross member 670 spans and connects opposing support members 672. Thecross member 670 supports a plurality of frame members 673. The framemembers 673 are positioned to correspond with the outer diameter of arotor 644 of the motor assembly (not shown). As shown in FIG. 15, therotor 644 seats on the cross member 670 and within the area formed bythe frame members 673. In this position, the frame members 673 supportthe rotor 644, thereby preventing or substantially reducing side-to-sidemovement and/or vertical movement of a suspended tub (not shown) andmotor assembly during shipping and handling of the washing machine.

Referring now to FIGS. 16 and 17, another embodiment of a framework thatmay be used as the interface is illustrated generally at 716. In thisembodiment, the engagement device 14 may be omitted. In this embodiment,cross member 770 spans and connects opposing support members 772. Thecross member 770 supports platform member 773. The platform member 773includes an aperture 775. The aperture 775 of the platform member 773 ispositioned to correspond with the outer diameter of a rotor 744 of themotor assembly (not shown). As shown in FIG. 17, the rotor 744 seatswithin the aperture 775 of the cross member 770. In this position, theplatform member 773 support the rotor 744, thereby preventing orsubstantially reducing side-to-side movement and vertical movement of asuspended tub (not shown) and motor assembly during shipping andhandling of the washing machine.

Referring now to FIGS. 18-20, another embodiment of a framework that maybe used as the interface is illustrated generally at 816. In thisembodiment, the engagement device 14 may be omitted. Referring first toFIGS. 18 and 19, the framework 816 includes intersecting support members872. The support members 872 support a first framing block 880 and asecond framing block 882. A gap 883 is formed between the first framingblock 880 and the second framing block 882. The gap 883 is configuredsuch that an engagement device, such as a resilient member 884 isinserted into the gap 883. As will be discussed in more detail below,the resilient member 884 is configured to support and cushion the rotor844, thereby preventing or substantially reducing side-to-side movementand vertical movement of a suspended tub (not shown) and motor assemblyduring shipping and handling of the washing machine. In the illustratedembodiment, the resilient member 884 is a hot and/or cold water hosesupplied with the washing machine and rolled into a stack within the gap883. The hot and/or cold water hoses may be configured to connect thewashing machine to the water supply at the consumer's residence.However, in other embodiments, the resilient member 884 can be otherstructures, members or devices.

Referring now to FIG. 20, the washing machine is illustrated generallyat 812. The washing machine 812 includes a bottom frame 834. In theillustrated embodiment, the washing machine 812 and the bottom frame 834are the same as, or similar to, the washing machine 12 and the bottomframe 34 discussed above and shown in FIG. 1. Alternatively, the washingmachine 812 and the bottom frame 834 can be different from the washingmachine 12 and the bottom frame 34. The framework 816 is installedwithin the washing machine 812 such that the rotor 844 rests on thesecond framing blocks 882 and within the area formed by the resilientmember 884. The ends of the first framing blocks 880 are positionedbetween the bottom frames 834 of the cabinet 820. In the illustratedembodiment, the first framing blocks 880 are retained within the cabinet820 as a result of a friction fit with the bottom frame 834 of thecabinet 820. In other embodiment, the framework 816 can be retainedwithin the cabinet 820 by other desired structures or mechanisms, suchas for example, clips or clamps.

The principle and mode of operation of the washing machine shippingsystems and methods have been described in certain embodiments. However,it should be noted that the washing machine shipping system and methodsmay be practiced otherwise than as specifically illustrated anddescribed without departing from its scope.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicant torestrict or in any way limit the scope of the appended claims to suchdetail. Additional advantages and modifications will readily appear tothose skilled in the art. For example, the specific locations of thecomponent connections and interplacements can be modified. Stillfurther, while rectangular and annular components have been shown anddescribed herein, other geometries can be used including polygonal(e.g., square, triangular, hexagonal, etc.), circular, etc. Therefore,the invention, in its broader aspects, is not limited to the specificdetails, the representative apparatus, and illustrative examples shownand described. Accordingly, departures can be made from such detailswithout departing from the spirit or scope of the applicant's generalinventive concept.

1. A washing machine shipping system for shipping a washing machinehaving a cabinet and a motor assembly having an external rotorpositioned within the cabinet, the shipping system comprising: anengagement device configured to mate with an outer surface of theexternal rotor of the motor assembly in a removable manner; and aninterface configured for retention at least partially within the cabinetof the washing machine during shipment; wherein the interface isconfigured to couple the engagement device and external rotor to thecabinet during shipment such that side-to-side movement of the motorassembly with respect to the cabinet is substantially prevented duringshipping and handling of the washing machine; wherein the interface isremovable from the cabinet after the shipping and handling of thewashing machine.
 2. The shipping system of claim 1 wherein theengagement device is removable from the outer surface of the externalrotor by pulling the engagement device linearly downward away from therotor.
 3. The shipping system of claim 1 wherein the engagement deviceincludes a plurality of slots that are sized and spaced to fit over aplurality of fins of the outer surface of the external rotor to mate theengagement device to the outer surface of the external rotor in aremovable manner.
 4. The shipping system of claim 1 wherein theengagement device is configured for use as a tool for preventingrotation of the rotor during servicing of the washing machine after theshipping and handling of the washing machine and removal of theinterface.
 5. The shipping system of claim 1 wherein the interfacecomprises wood frame members.
 6. The shipping system of claim 1 whereinthe washing machine includes a tub associated with the motor assemblyand wherein a damping element is stretched over and attached to a tub.7. The shipping system of claim 1 wherein the washing machine includes abasket positioned within the cabinet and wherein a removable plugextends from the basket to the cabinet, the removable plug configured toprevent movement of the basket relative to the cabinet.
 8. A method forshipping and handling a washing machine having a cabinet and a motorassembly with an external rotor positioned within the cabinet, themethod comprising: removably mating an engagement device with an outersurface of the external rotor; coupling the engagement device andexternal rotor to the cabinet during shipment such that side-to-sidemovement of the motor assembly with respect to the cabinet issubstantially prevented during shipping and handling of the washingmachine; decoupling the engagement device and the external rotor fromthe cabinet after said shipping and handling of the washing machine. 9.The method of claim 8 further comprising removing the engagement devicefrom the external rotor after said shipping and handling of the washingmachine by pulling the engagement device linearly downward from theexternal rotor.
 10. The method of claim 8 wherein the engagement deviceincludes a plurality of slots that are sized and spaced to fit over aplurality of fins of the outer surface of the external rotor to mate theengagement device to the outer surface of the external rotor in aremovable manner.
 11. The method of claim 8 further comprisingstretching a damping element over a tub of the washing machine.
 12. Themethod of claim 8 further comprising positioning a plug in an opening ofthe cabinet and the opening of a basket of the washing machine toprevent movement of the basket relative to the cabinet.
 13. A washingmachine shipping system for shipping a washing machine having a cabinetand a motor assembly that includes an external rotor positioned withinthe cabinet, the shipping system comprising: a removable frameworkretained at least partially within the cabinet of the washing machine,the removable framework including a plurality of support membersconfigured to support at least one cross-member; wherein the crossmember is configured to engage an outer surface of the external rotor ina manner that substantially reduces side-to-side movement of the motorassembly within the cabinet during shipping and handling of the washingmachine.
 14. The shipping system of claim 13 wherein a plurality offrame members are attached to the cross member, the plurality of framemembers being positioned to correspond to an outer diameter of theexternal rotor of the motor assembly.
 15. A washing machine shippingsystem for shipping a washing machine having a cabinet and a motorassembly that includes an external rotor positioned within the cabinet,the shipping system comprising: a plurality of intersecting supportmembers forming a framework; a plurality of framing blocks attached tothe intersecting support members, the framing blocks configured todefine a gap; and a resilient member positioned within the gap; whereinthe framework is retained within the cabinet of the washing machine andconfigured to support the external rotor of the motor assembly; whereinthe resilient member is configured to substantially reduce side-to-sidemovement of the motor assembly within the cabinet of the washing machineduring shipping and handling of the washing machine.
 16. The shippingsystem of claim 15 wherein the resilient member is at least one hosesupplied with the washing machine for connecting the washing machine toa water supply.